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Using Syngas to make DRI

in the MIDREX Process

Designed for Today,


Engineered for Tomorrow

CONTENTS

DIRECT REDUCTION USING COAL

COKE OVEN GAS (COG)

COMMERCIAL GASIFICATION

5 COREX EXPORT GAS


6

ADVANCED TECHNOLOGY DEVELOPMENT

ENVIRONMENTAL ASSURANCE
Midrex Technologies, Inc. along with its parent company Kobe Steel, Ltd., recognizes the importance of protecting the
environment and conserving natural resources. Through the years we have been proactive in increasing efficiency,
productivity, reliability and safety while reducing the environmental impact of our processes.
MIDREX Plants are designed to minimize water, noise and air pollution.
MIDREX Plants meet applicable World Bank standards and more importantly, Midrex can and will provide DRI Plants
designed to meet any local emissions or environmental standards regardless of location.

Using Syngas to make DRI


in the MIDREX Process

The MIDREX Process - The worlds most reliable


and productive Direct Reduction Technology

Designed for Today,


Engineered for Tomorrow

Designed for Today,


Engineered for Tomorrow

Designed for Today,


Engineered for Tomorrow

MIDREX Process

Building DRI Plants

Optimizing DRI production


using natural gas

MIDREX NG

MXCOL

MXCOL CONTENTS

Designed for Today,


Engineered for Tomorrow

Building DRI Plants

DRI Products
& Applications

Designed for Today,


Engineered for Tomorrow

DRI Products &


Applications

DIRECT REDUCTION USING COAL


MXCOL (PRONOUNCED M-X-COAL) IS THE NAME AND TRADEMARK FOR THE USE OF SYNGAS DERIVED
FROM COAL IN THE COMMERCIALLY PROVEN MIDREX DIRECT REDUCTION PROCESS.
Syngas, or synthesis gas, is a gas mixture consisting of
hydrogen, carbon monoxide and carbon dioxide resulting
from the gasification of a carbon-containing fuel. Midrex
commercially offers technology utilizing syngas derived from
natural gas and coal sources. These technologies include:
MXCOL, COREX/ MXCOL and the new MIDREX Thermal
Reactor System (TRS).
MXCOL can use reducing gas from several sources of
syngas: commercial gasifiers using a variety of low cost fuels,
export gas from the coal-based COREX Hot Metal Process
by Siemens VAI Metals Technologies GmbH, and the innovative MIDREX Thermal Reactor System (TRS).
The first commercial application of MIDREX Technology
using syngas from coal was commissioned in 1999 at
ArcelorMittal Steel South Africa (formerly Saldanha Steel).

Here the export gas from a COREX Plant is used in a


MIDREX Shaft Furnace to supply DRI to the meltshop in
addition to the hot metal from the COREX Plant.
Jindal Steel & Power Limited (JSPL) has built the first
MIDREX Direct Reduction Plant based on commercially
available coal gasification technology in Angul, Odisha, India.
The plant will use indigenous coal and iron ore to produce
both hot and cold direct reduced iron (DRI) for use in an
adjacent meltshop.
The Thermal Reactor System (TRS) uses a new partial
oxidation technology to convert hydrocarbon fuels into high
quality, high temperature syngas suitable for DRI production.
The TRS will allow the production of DRI with a variety of
fuels, including coke oven gas.

DIRECT REDUCTION USING COAL

MXCOL

COKE OVEN GAS (COG)


COKE OVENS GENERATE AN OFFGAS CONTAINING HYDROGEN AND CARBON MONOXIDE. THIS GAS
CAN BE USED FOR FEEDSTOCK FOR CHEMICAL PRODUCTION, HEATING APPLICATIONS AND ELECTRICITY
GENERATION; HOWEVER, THE CHEMICAL ENERGY OF COG CAN MOST EFFICIENTLY BE USED BY STEELMAKERS TO CREATE ADDITIONAL IRON UNITS.
MIDREX THERMAL REACTOR SYSTEM (TRS)
Midrex and Praxair have partnered to develop the Thermal Reactor System (TRS) technology that will reform COG for use
in a MIDREX Shaft Furnace. The TRS reforms the cyclic and long chain hydrocarbons to make the resulting exhaust gas into
a usable and efficient reducing gas.
Midrex has created two options for utilizing COG via the TRS for DRI production.The first option uses and recycles COG for
situations where the COG can be specifically allocated for DRI production. The second option - the Once-Thru flowsheetallows clients to utilize some of the fuel value of their COG for other purposes while still enabling COG to be utilized for DRI
production.

MXCOL COG RECYCLE

Clean
Coke Oven Gas
(COG)

COG
Pre-Heater

Thermal
Reactor
O2

JSW DOLVI WORKS

Iron Oxide

Recycle Gas

MIDREX
Shaft Furnace

Scrubber
CO2
Removal

Syngas
Gas
Heater

Air
Separation
Plant

Thermal Reactor System

Reducing Gas

MXCOL COG ONCE-THRU

Clean
Coke Oven Gas
(COG)

CDRI / HBI / HDRI

MXCOL Plant

Iron Oxide

Export Fuel
COG
Pre-Heater
Scrubber
MIDREX
Shaft Furnace
Thermal
Reactor

Reducing Gas

O2
Air
Separation
Plant

Thermal Reactor System

MXCOL Plant

CDRI / HBI / HDRI

MXCOL MXCOL COKE OVEN GAS

JSW Steel Ltd. and Midrex are modifying


the existing MIDREX Direct Reduction
Plant at JSWs steelworks in Dolvi,
Maharashtra, India, to be the first to use
coke oven gas (COG) as a supplement to
natural gas for DRI production. This feature
will provide the flexibility to operate the
plant efficiently under a wide range of
parameters.

COMMERCIAL GASIFICATION
GASIFICATION REFERS TO THE REACTION OF COAL OR OTHER SOLID OR LIQUID CARBONACEOUS FEEDSTOCK WITH OXYGEN TO PRODUCE A SYNTHESIS GAS (SYNGAS). THE ADVANTAGE OF GASIFICATION IS
THAT USING THE SYNGAS IS POTENTIALLY MORE EFFICIENT THAN DIRECT COMBUSTION OF THE ORIGINAL
FUEL. SYNGAS MAY BE USED TO GENERATE A HIGH QUALITY REDUCING GAS FOR PRODUCTION OF DRI.
MXCOL GASIFIER OPTION
Iron Oxide
Coal
Pet Coke
Refinery Bottoms
Recycle Gas
Gasifier
O2
Air
Separation
Plant

Gas

Cleaning &
Conditioning

MIDREX
Shaft Furnace

CO2
Removal
Scrubber

Syngas

Gas
Heater
Turbo Expander

Gasification Plant

MXCOL Plant

MXCOL GASIFIER SYNGAS SOLUTION


Commercially available gasification technology can be paired
with a MIDREX Shaft Furnace to produce any form of DRI (cold
DRI, hot DRI, or HBI). The gasification syngas option includes
gas-cleaning and conditioning systems, which prepare the syngas
for reheating to the ideal temperature for use as reducing gas. The
offgas from the reduction furnace is mixed with fresh syngas after
scrubbing and CO2 removal, reheated and recycled to the furnace.
A very high quality syngas can be produced by gasification technology regardless of the quality of the fuel. This allows for use
of various bituminous and sub-bituminous coals, lignite, pet
coke and petroleum refinery bottoms. In cases where natural gas
availability is uncertain or when energy costs rise, the gasification
syngas option can provide a beneficial alternative.

CDRI / HBI / HDRI

JINDAL STEEL & POWER LTD.

Gasification technology supplied by Lurgi


GmbH is being used to generate syngas for
the 1.8 million ton per year MIDREX Direct
Reduction Plant at Jindal Steel & Power
Limited s steelworks. The gasifier will use
indigenous coals and the MIDREX Shaft
Furnace will operate with local iron ore.

COMMERCIAL GASIFICATION

MXCOL

COREX EXPORT GAS


THE APPLICATION OF EXPORT GAS FROM THE COREX HOT METAL PROCESS AS REDUCING GAS FOR THE
PRODUCTION OF DRI IN A MIDREX SHAFT FURNACE HAS BEEN AN OPERATIONAL REALITY SINCE 1999.

COREX OFFGAS
An MXCOL Plant based on the use of COREX export gas is capable of providing blast furnace-grade hot metal and high
quality DRI. The COREX Plant uses a melter/gasifier to simultaneously produce hot metal and export syngas. After scrubbing
and CO2 removal, the reductants-to-oxidants ratio of the COREX export syngas is boosted to greater than 10. The prepared
syngas is then heated to the target reduction temperature and introduced into the MIDREX Shaft Furnace. The export gas
from the MIDREX Shaft Furnace is mixed with fresh COREX export syngas after scrubbing and CO2 removal, reheated and
recycled to the furnace.
Benefits of the MXCOL Flowsheet using COREX export gas over the coke oven-blast furnace route include lower environmental
impact and improved economies of scale.

COREX/ MXCOL OPTION


Iron Oxide
Additives/
Ore/Pellets
Reduction
Shaft

COREX
Export
Syngas

Top Gas

Coal
Scrubber
Gasifier
Melter

Recycle Gas

CO2
Removal

MIDREX
Shaft Furnace
Scrubber

Gas
Heater

O2
Slag

COREX Plant

Hot Metal

CDRI / HBI / HDRI

MXCOL Plant

ARCELORMITTAL SOUTH AFRICA


In addition to the COREX/
MXCOL Plant in Saldahna
Bay South Africa, a second
such plant has been
constructed for JSW Steel,
Ltd. in India.

MXCOL COREX EXPORT GAS

ADVANCED TECHNOLOGY
DEVELOPMENT
MIDREX HAS BEEN AT THE FOREFRONT OF DRI TECHNOLOGY DEVELOPMENT FOR MORE THAN 40 YEARS.
MUCH OF THE COMPANYS RESEARCH AND DEVELOPMENT HAS BEEN FOCUSED ON COMMERCIAL
TECHNOLOGY SOLUTIONS TO PRODUCE DRI UTILIZING VARIOUS FUEL SOURCES INCLUDING NATURAL
GAS, COAL, COG AND PROCESS SYNGAS.
Midrex has been steadfast in its mission to expand the direct
reduction industry to embrace fuel sources other than natural
gas. Since the commissioning in 1999 of the first MIDREX
Shaft Furnace to use a syngas derived from coal as reducing
gas, Midrex is the only technology supplier to have commercial-scale DRI reduction furnaces in operation that use syngas
derived from coal to make DRI.
Midrex has joined with leading companies in their fields
including Siemens VAI Metals Technologies GmbH, Paul
Wurth S.A., Lurgi GmbH, Synthesis Energy Systems, Inc. and
Praxair, Inc. to identify and develop innovative solutions for
generating and using syngas to use as reducing gas for direct
reduction.
Midrex is involved in multiple projects based on syngas
produced by a coal gasifier, a COREX Plant or from the off gas
of a coke oven to supplement natural gas. These include JSPL
Angul Ithe worlds first DRI Plant paired with a coal gasifier
located in Angul, Odisha, India. JSW Projects Ltd., a group
company of JSW Steel Ltd., has built another COREX/
MIDREX Plant featuring multiple discharge options. This
new facility is at JSW Steel Ltd., located in Toranagallu,
Karnataka, India. Lastly, JSW Dolvi is modifying their existing
MIDREX Plant to utilize coke oven gas (COG) to supplement
its natural gas supply. The plant is located at the JSW-Dolvi
Works (formerly JSW Ispat, Ltd.) Dolvi, Maharashtra, India.

In addition, a large-scale demonstration facility at the Midrex


Technology Center has been operated for more than 1000
hours to prepare the Thermal Reactor System (TRS) for
commercialization by Midrex and Praxair.
The benefits of direct reduction, which were once available
only to those with abundant sources of cheap natural gas, are
now fueling a new paradigm in global steelmaking.

JSPL ANGUL

The worlds first DRI Plant with coal gasifier at JSPL


Angul I, India began operation in 2014.

ADVANCED TECHNOLOGY DEVELOPMENT MXCOL

www.midrex.com
USA / CORPORATE HEADQUARTERS:
Midrex Technologies, Inc.
2725 Water Ridge Parkway
Suite 100
Charlotte, NC 28217 USA
Tel: +1 (704) 373 1600
Email: sales@midrex.com

UK:
Midrex UK Ltd.
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London, SE1 9RA
United Kingdom
Tel: +44(0)207 0891520
Email: info@midrex.com

CHINA:
Midrex Metallurgy Technology Services
(Shanghai) Ltd.
1505 Park Place
1601 Nan Jing West Road
Shanghai 200040 PRC
Tel: +86 21 61573700
Email: sales@midrex.cn

INDIA:
Midrex Technologies India Private, Ltd.
Global Foyer, Golf Course Road
Gurgaon-122002, Haryana | India
Tel: 0124-4908712
Email: sales@midrex.in

Aug 2014